A New Mitigation Strategy for Failures in Metallized Polypropylene
Capacitors
Joseph Bond
Operations and Engineering Manager
Electronic Concepts, Inc.
is a momentary short where the energy
stored in the capacitor creates a shortduration high current which causes the metal
at the fault point to vaporize. Although this
can prolong the life of the metallized
polypropylene device, certain precautions
must be taken to assure that the device does
not destroy itself after multiple self-healing
cycles.
Film-foil capacitors which fail as a dead
short can be protected with fuses or current
sensors to alert the user of a high current
condition. However in metallized
polypropylene devices many self-heal cycles
can result in excessive leakage currents and
increased power losses.
Metallized polypropylene capacitors fail
differently depending on whether the
application is in a DC or an AC circuit.
DC applications with excessive self-heal
cycles will exhibit an increased geometric
center or “hot spot” temperature which
decreases the breakdown voltage of the
dielectric.
In AC applications the low resistance short
due to self-healing will vary from a few
ohms to a few hundred ohms. (New
capacitors exhibit a resistance in the microohm to the milliohm range.) This higher
ESR contributes to higher I2R generated
heat. As core temperature increases, the
dielectric strength of the capacitor is
weakened which leads to further dielectric
breakdown.
Failures in both DC and AC applications
are thermally generated. Since the failure in
AC applications is more likely to result in
Abstract
Metallized film capacitors utilizing
polypropylene dielectric have become the
component of choice in critical applications
because of their low dielectric loss and
superior breakdown voltage strength. There
are some concerns that in certain
applications metallized polypropylene
capacitors can fail in a manner such that the
failure poses a hazard to the equipment and
personnel. FuseacTM is a thermal fuse
technology designed to protect against
common capacitor failure modes in high
power AC and DC applications. FuseacTM
technology will deploy upon sensing a
temperature beyond its preset limit and
electrically disconnect, providing protection
against catastrophic failures by rendering the
capacitor electrically open.
Background
Metallized polypropylene dielectric for
capacitors is fabricated by vapor depositing
an aluminum or zinc-aluminum metal
electrode to a polypropylene substrate that
serves as the dielectric. This structural
profile promotes self-healing at a fault by
vaporizing the electrode at the point of the
fault. Older technology film-foil capacitors
using heavy foil electrodes in the windings
would fail as a short but the foil was too
thick to vaporize and the failure could not be
reversed.
Metallized electrodes do not fail as a
permanent short. At the failure point there
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combustion (as opposed to an open circuit in
DC circuits), and combustion failures have
been observed with less than10% increase in
line current, a method to monitor the core
temperature of the capacitor for “hot spots”
was needed so that the device can be
electrically removed from the circuit before
combustion occurs.
temperature difference between the “hot
spot” and the external case. The external
case temperature can be markedly lower
than the internal hot spot, depending on the
diffusion of heat through the dielectric and
case (independent of ambient). The rate of
heat transfer from the “hot spot” to the
external case is often too slow to detect a
critical condition and physical placement of
the capacitor relative to ambient cooling can
affect a case-mounted sensor. ECI’s
thermally activated electrical disconnect,
known as FuseacTM, deploys an internal
thermal fuse that is triggered by
temperature. Advantages of this type of
thermal fuse include failure detection and
disconnect before a fire condition. FuseacTM
also allows a rigid connection to the unit
with no mounting restrictions. Other
advantages include enclosed dry
construction (no oil or electrolyte), no case
ruptures during disconnect, smaller size,
lighter weight and cost effectiveness.
Compare these advantages to a mechanical
disconnect capacitor construction with a
break away connection triggered by gas
build up within the case. Mounting for
mechanical disconnect devices requires
flexible connecting lines, sufficient space for
expansion above the connections, and is
restricted to a vertical orientation. Gasses
created during self-healing create intentional
case deformation to disconnect the
capacitor. Potential rupture of the package
can result in oil leakage and system
contamination. FuseacTM is a marked
improvement over conventional mitigation
strategies and directly addresses these
critical application and reliability issues.
Failures in Metallized
Polypropylene Capacitors
Failures in metallized film capacitors can
be triggered by excessive total line
frequency and PWM current above rating;
excessive AC voltage above rating; transient
voltage spikes above the dielectric
withstanding voltage (DWV) rating; ambient
temperatures in excess of 85OC; terminal
connection problems relative to shock or
vibration; exceeding packaging
environmental conditions including
moisture; excessive clearings or corona
induced from an uncontrolled event.
Conventional AC capacitor protection
considerations include current sensing
controls such as electrical fuses,
management of voltage overrun conditions,
heat management including ambient control
(fan/cooling), thermal sensing on the body
of the capacitor, and capacitor
placement/location, e.g., isolation from heat
sources. These are issues associated with
these types of protection.
In AC circuits using metallized film
capacitors protected by electrical fuses,
dielectric flaws, stressed by one of the
aforementioned events, can create internal
momentary current spikes as partial
discharges generate self-healing. The
capacitor remains functional in the circuit
through self healing and the electrical fuse
remains closed which can lead to
catastrophic failure. External thermal
sensing attempts include monitoring the
FuseacTM
FuseacTM is a thermal fuse technology
designed to protect against catastrophic
capacitor failure potential resulting from
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common capacitor failure modes in high
power AC and DC applications. FuseacTM
technology will deploy upon sensing a
temperature beyond its preset limit and
electrically disconnect, providing protection
against catastrophic failures by rendering the
capacitor electrically open. ECI’s UL
certified 5MPF series AC capacitors employ
FuseacTM technology at 300, 600 and
900vac ratings for inverter output filtering.
FuseacTM can be incorporated, on request, in
a host of Electronic Concepts, Inc. products,
especially for designs needing added
overheating protection.
product application. An additional means is
required within the device to assure the
safety of both equipment and personnel.
This is accomplished by incorporating
FuseacTM in the polypropylene film
capacitor. Unlike mechanical safety
mechanisms described earlier, FuseacTM
disables the capacitor before it reaches
combustible temperatures, thus offering an
additional safety margin in critical
applications.
Conclusion
Polypropylene film capacitors offer many
advantages in large power applications.
Their physical size and higher bandwidth
make them highly suitable as a preferred
alternative to other technologies. Process
controls and monitoring contribute to their
reliable field performance. The addition of
FuseacTM temperature protection makes
them even more desirable for applications
where high reliability, circuit protection and
isolation are imperative.
Quality and Reliability
Self-healing metallized polypropylene
capacitors fail due to avalanche breakdown
caused by multiple self-healing events as
temperature increases. Incorporating
FuseacTM in the capacitor will safeguard
against these catastrophic temperaturegenerated failures, but additional measures
are also taken during the manufacturing
process to characterize potential failures in
the metallized film. Some of these
safeguards include:
-At incoming inspection of the
dielectric film both voltage fault tests
and avalanche tests are employed to
assure film integrity.
-To assure clearing events are
minimized, an overvoltage potential
in excess of the rated DWV voltage
is applied during capacitor
production.
While these measures significantly
improve product reliability, they cannot
prevent clearings due to voltage transients or
excessive temperature excursions during the
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